how nasa balances safety & risk in harsh environments trey hall the rothe companies with team...
TRANSCRIPT
How NASA Balances Safety & Risk in Harsh Environments
Trey Hall
The Rothe Companies
With Team Raytheon
Similarities – Space & Subsea Operating in Remote, Hostile Environments
(Except weight and opposite pressure gradients)
Subsea Fields & Lunar/Mars Settlements
Astronauts & Divers
Historically Common Roots
Satellites & Capping Stacks
We Have a Lot to Learn from One Another
We’ve grown up independently, But never really compared notes, Though we’re close neighbors. We’re learning tough lessons. We’re meeting the Challenges of Complex Modern Systems.
It’s time to compare notes….
Capturing Lessons-Learned & Improving
Benchmarking Best Practices
Macondo
Piper Alpha
Challenger
Columbia
Planning & Execution Command & Control
Architecture
Emergency Response, Crisis Mgmt
Simulations, Joint Integrated Sims
Teamwork, Coordination, & Communication Protocol
Murphy Evolves & Lives!• Growing Systems
Sophistication Require Sophisticated Systems Engineering & Management– Advanced Systems Take ~7
Combined Failures to Create Catastrophic Results
• Yet, Our Human Nature Resists Change• Repeated Mistakes and Lessons-Learned• We Still Succumb to Budget & Schedule Pressure• We Still Engage in Group Think and Shared Rationalisms• We Still Create Faulty Consensus and the Illusion of
Invulnerability
Challenges & Course Corrections• With System Advances and
Stubborn Human Tendencies, We Must Remain Vigilant and Aware
• Arrogance in the Face of Subtle (and not-so-Subtle) Warnings Can be Deadly• Key Component: Humility
• Real Possibility that Comprehensive Worker Understanding may Decrease with Growth in Systems Sophistication
• Separating Noise from Important, Actionable Data
Challenger & Columbia
• Similar Themes to Piper-Alpha, Macondo• Key Contributor: Command & Control Architecture,
Communications Protocol, affected by different cultures in Management, Engineering, & Operations
• Dissenting Opinions Were Not Effectively Heard or Listened To
• Intimidation Lead to Acquiescence • Ultimate Consequences Were Realized
• Challenger Cold O-Rings Blowby Explosion• Columbia Ice Wing Leading Edge Crack Plasma Structural Failure
The Pull Towards Disaster
• The More Momentum that is Gained Towards a Decided Action, and the Nearer it is in Time, the Harder it is to Change Direction– This is True Even in the Presence of New Information that Would Have
Otherwise Changed the Original Decision• Challenger Launch Delayed Twice, Agency Under Schedule Pressure,
Funding Being Debated in Congress• Cold Temperatures at the Launch Pad Were Below O-Ring Specifications
• Even After an Issue has been Identified, Blinders may Actively Prevent Presentation of New Important Information or Capabilities that Could Change the Ultimate Outcome– Satellite Survey of Shuttle Wings Offered But Rejected
Change
• Because of Genuine Reflection, Self Study, and Industry Best-Practices Benchmarking, NASA has Reassessed Certain Practices
– Recognize, Elevate, and Evaluate Dissenting Opinions– Institute Training to Identify and Avoid Group Think, and
Encourage Situational Awareness• Create Open Communication Climate• Avoid Isolation; Encourage Participation• Implement Critical Evaluations; Independent Opinions (Devil’s
Advocates)
Technical Competence & Preparation• Looking at Data From Multiple Viewpoints to Ensure
Understanding• Safety Professional Credibility
– Earned Through Competency, Trust, Collaboration
• Ability to Recognize or Identify When Table-Top Training or Computer Simulations Are Not Enough
• NASA Trains Astronauts for ExtraVehicular Activities using Table-Top & Virtual Reality Training, But Also Underwater in a High-Fidelity, 3-D Physically-Accurate Environment.
• Nothing Else Quite Compares, and More Sufficiently Identifies Issues
Neutral Buoyancy Lab 102’ wide x 202’ long x 40’ deep; 6.2M Gal FW; ~86 deg F., Controlled, Instrumented Environment
Reliable Up-Time, Even in Inclement Weather Vertically-Integrated Capabilities (Configuration, Testing, Simulation, Animation, Engineering, Manufacturing, Logistics, & Dive Staff)
ISO 9001-2008 Facility
World Class Safety OSHA VPP Star of Excellence multiple-awardee
No Lost Time: In-water Dive Ops: 183,622 + hours
No Lost Time: Days Away Incidents for 1792 + Days
No Lost Time: Restricted Work Cases for 2656 + Days
#’s as of June 2013
Safety Cultures are Similar
Safety & Test Readiness Reviews, Pre-Op & Post-Op Reviews
NBL Capabilities On-site Oceaneering Millennium Working Class ROV Inspection-Class ROV Two High Bays for Integration, Staging and Test Overhead/Overwater Bridge Cranes, Jib and Davits Dive Ops/SCUBA; Nitrox, Air, Surface-SupplyUnderwater Video & Comm; Control Rooms; IT & Data Systems; Conference & Classrooms.Vertically-Integrated Capabilities: Engrg thru Mfg.
Real-Time Brainstorming & Problem Solving Rapid Prototyping, Design-Fab-Test Cycles Concept ROV-Operable BOP Panels Fully-Functional Intervention Interfaces
NASA Use & Background NASA Enhances Simulation, Virtual Reality, and Table Top Training with In-Water “0-g” Training Complex Operations in Remote, Hostile Environment High Consequence Operations Requiring High Confidence and Control
Process/Procedure Development, Optimization Key Steps to Success
Nominal Task, Off-Nominal Response Anticipated & Prepared-For in Advance Makes the Unexpected More Manageable
Why is the NBL Available? Shuttle Retired Space Station Assembly is Complete Less Astronaut Training Creating “Excess Capacity”
We’re making this National Asset available to external users
Oil & Gas is a Natural Fit
The NBL is a great Test Basin for O&G
Pipeline Inspection Test Articles
Mfg Facility
Why Use the NBL? Computer Sims and Dry SITs are Incredibly Valuable, but Sometimes Not Enough for Complex Systems and Tasks.
Computer Sims can add environmental conditions (current, turbidity), large-scale functionality, but can be idealistic Augment Sims and Dry SITs with 3-D, Hi-Fi Submerged Test Environment (Wet SITs)
Improve Safety Save Time Reduce Expense
Vessel Mob/DeMob, Vessel Day Rates, Execution Delays, Work Replanning, Re-Work
Why Use the NBL? Improve Confidence; Increase Test Realism Accelerate Critical Project Schedules Optimize Productivity & Efficiency of Key Houston-Based Resources Maximize Situational Awareness Improve Wet SIT Reliability
Near 100% Facility Uptime Increase Simulation and Training Fidelity
Actual Underwater Environment Buoyancy, Resistance, Added Mass
Full Use of System Controls Thrust, Tool Behavior, System Response
Reduce Operational Risk Define Task Requirements, Refine Processes and Procedures, Optimize Timelines, Perform Efficiency Trade Studies
Why Use the NBL? Improve Preparation; Ensuring Operational Readiness prior to moving to deepwater environment. Enhance Project Execution; Improve Data upon which to base real-time decisions Improve Ability to React to Unexpected Events Optimize Training to Verify Competency in Advance Example: Agbami West Africa Subsea Project
36 Missions: 18 As-Planned; 15 Modified Real-Time; 3 Failures Totally Re-Planned Real Time
Diver Supported Testing
Applications in Oil & Gas and Deep Offshore Technology
Autonomous Underwater Vehicle Testing & Development
3-D Mapping Subsea Technology Research & Development Testing
Pipeline Inspection, Down Hole Sensors, Etc.
Atmospheric Dive Systems Tests & Certification Lloyd’s Certification
Applications in Oil & Gas and Deep Offshore Technology
Cascade Chinook FSHR Buoyancy Can Chain Inspection and Repair Feasibility & Solution Trade Studies Prototyping & Hardware Production 10 day SIT
Thunder Horse Water Injection Process Development; 22 day SIT Working Class ROV Systems Integration Testing
Applications in Oil & Gas and Deep Offshore Technology
OPITO-approved Safety & Survival Training, including HUET, BOSIET, Major Emergency Management (MEM)Training (Similar to NASA Flight Controller Training)
Underwater Systems Integrated Ops: AUVs, ROVs, ADSs
Integrated Engineering and Manufacturing
Animation & Simulation
Future Applications in Oil & Gas Broad Scale Joint Integrated Sims Compliance for ROV Pilots (BOP Intervention) ROV Test &Training Center of Excellence Best of All Worlds – Training, Simulation, Wet SITs,
Competency, Confidence
Where? In Your Backyard
Only 22 Miles from Downtown Houston
Conclusion
When There is Only One Chance to Safely Do It Right, or as an Intermediate Step to Sea Trails, Enhance Preparation and Execution with High-Fidelity Wet SITs in a Local, Reliable, Controlled Environment, Saving Time and Resources.
Reduce Complex Operations Risk in Hostile, Remote Environments.
Over the Years, NASA – like Offshore Oil & Gas – has Learned Valuable Lessons in Managing Risk and
Improving Safety Through Communication, Recognition of Human Traits, Maintaining Vigilance, and Improving
Preparation Through High-Fidelity Simulations.
You’re Invited; Come See Us!
Contact information
Trey Hall, V.P./C.O.O.
The Rothe Companies
NBL External Customer Office Manager
C: 713-829-7466
www.Rothe.com
Or, Contact NASA or any of our Team Mates